Flat consumable article for aerosol generating devices

Abstract

The flat consumable article (30) extends along an article axis (Y) and along an article plane (A) parallel to the article axis (Y), and includes a tobacco portion and a mouthpiece portion disposed along the article axis (Y). The mouthpiece portion (34) includes a corrugated core material (50) and at least one planar support (60) that supports the corrugated core material (50), and the corrugated core material (50) is attached to the at least one planar support (60).

Description

[Technical Field]

[0001] The present invention relates to a flat consumable article for an aerosol generating device, for example, the flat consumable article presents a solid substrate that can form an aerosol when heated.

[0002] The flat consumable article according to the present invention is configured to operate in conjunction with an aerosol-generating device. These types of aerosol-generating devices, also known as non-combustion heated devices, are adapted to generate an aerosol for inhalation by heating, rather than burning, a substrate through conduction, convection, and / or radiation. [Background technology]

[0003] In contrast to tobacco combustion devices, a variety of devices are available that heat or warm the vaporizable material in traditional tobacco products.

[0004] For example, such devices may be substrate-heated aerosol generating devices or heat-and-burn devices. This type of device typically generates an aerosol or vapor by heating an aerosol substrate containing moist tobacco or other suitable vaporizable material, typically to a temperature ranging from 150°C to 350°C. By heating the aerosol substrate but not burning or igniting it, an aerosol is released that contains components desired by the user but that are not the toxic and carcinogenic byproducts of combustion and ignition. Furthermore, because aerosols generated by heating tobacco or other vaporizable material typically do not contain the burnt or bitter taste that can result from combustion and ignition, which can be unpleasant to users, the substrate, therefore, does not require the sugars and other additives typically added to such materials to make the smoke and / or vapor more palatable to the user.

[0005] For example, the aerosol substrate used is a flat consumable article comprising a tobacco portion and a mouthpiece portion, the flat consumable article being intended to be at least partially received within a heating chamber of an aerosol generating device, the mouthpiece portion allowing vapor to cool and travel from the tobacco portion to an outlet of the consumable article.

[0006] It is very important that the flat consumable article does not collapse during handling, when inserted into the aerosol generating device, or during use in the device, as collapse of the flat consumable article may block or impede the flow of vapor. Summary of the Invention [Problem to be solved by the invention]

[0007] An object of the present invention is to provide a flat consumable article that has better resistance to deformation and can be easily manufactured. [Means for solving the problem]

[0008] To this end, the present invention relates to a flat consumable article for an aerosol generating device, the flat consumable article extending along an article axis and along an article plane parallel to the article axis, said flat consumable article comprising a tobacco portion and a mouthpiece portion arranged along the article axis, the mouthpiece portion comprising a corrugated core material and at least one planar support supporting the corrugated core material, the corrugated core material being attached to at least one planar support.

[0009] These features allow flat consumable articles to exhibit greater deformation resistance and be easier to manufacture. The corrugated core increases the compression resistance of the mouthpiece portion. In fact, the corrugations of the core increase the bending strength of the core in a direction perpendicular to the corrugations. The planar support further increases the deformation resistance of the consumable article.

[0010] According to some embodiments, the corrugated core, together with the at least one planar support, defines a plurality of channels extending substantially parallel to the article axis.

[0011] Due to these characteristics, the corrugated core allows for efficient and consistent vapor flow through the mouthpiece portion.

[0012] According to some embodiments, the corrugated core comprises a sheet, the sheet comprising two opposing non-planar surfaces, the non-planar surfaces being defined by generatrix lines that are straight lines substantially parallel to the article axis, the generatrix lines extending from directrix lines that correspond to non-zero periodic functions.

[0013] By virtue of these characteristics, the corrugated core presents a shape that simultaneously enhances the deformation resistance of the consumable article while promoting vapor flow through the mouthpiece portion.

[0014] According to some embodiments, each non-planar surface of the sheet includes a longitudinal edge extending longitudinally along the article axis, and at least one planar support contacts the longitudinal edge of the corresponding non-planar surface.

[0015] By virtue of these features, the planar support supports the corrugated core along regularly spaced lines, and deformation resistance is uniformly enhanced across the mouthpiece portion.

[0016] According to some embodiments, the orthogonal projection of the corrugated core onto the plane of the article is included in the orthogonal projection of the at least one planar support onto the plane of the article.

[0017] Thanks to these features, the corrugated core is entirely supported by the planar support, and deformation resistance is increased throughout the entire mouthpiece portion.

[0018] According to some embodiments, the corrugated core is glued or welded to at least one planar support.

[0019] These features further improve the deformation resistance of the consumable article. In addition, manufacturing of the consumable article becomes easier because the corrugated core and the planar support are bonded to each other. Movement of the corrugated core relative to the planar support is prevented.

[0020] According to some embodiments, the at least one planar support is made of paper, cardboard, or film.

[0021] Thanks to these characteristics, the planar support can be made of common materials that meet deformation resistance characteristics and do not pose a risk to the user.

[0022] According to some embodiments, the flat consumable article further comprises a wrapper encasing at least the mouthpiece portion.

[0023] These features prevent condensation from forming inside the aerosol generating device. In effect, the wrapper prevents generated vapor from escaping from the article inside the device and condensing within the heater. The corrugated core and planar support prevent the wrapper from collapsing. Conversely, the wrapper holds the corrugated core and support or board in place within the consumable article.

[0024] According to some embodiments, at least one planar support is attached to the wrapper.

[0025] These features further improve the deformation resistance of the consumable article because the corrugated core, the planar support, and the wrapper are mechanically bonded to one another, and for the same reasons, manufacturing of the consumable article is easier.

[0026] According to some embodiments, the flat consumable article includes at least two planar supports configured to support the corrugated core.

[0027] Thanks to these features, the flat consumable article exhibits greater resistance to deformation.

[0028] According to some embodiments, each planar support contacts a longitudinal edge of a corresponding non-planar surface.

[0029] These features allow the corrugated core to be supported by planar supports along regularly spaced lines on both sides, further enhancing deformation resistance uniformly across the mouthpiece portion on both sides of the corrugated core.

[0030] The present invention also relates to a method for producing the flat consumable article described above, said method comprising the steps of: - providing a tobacco portion; - preparing a mouthpiece portion such that a corrugated core is attached to at least one planar support; - positioning the tobacco portion and the mouthpiece portion along an article axis; - attaching the tobacco portion and the mouthpiece portion to each other; Includes.

[0031] These features make the planar support easier to manufacture the consumable article because the planar support can support the corrugated core during the assembly process of the consumable article.

[0032] According to some embodiments, the step of creating the mouthpiece portion includes attaching a corrugated core and at least one planar support to form the mouthpiece portion.

[0033] These features make flat consumable articles easy to manufacture.

[0034] According to some embodiments, the step of fabricating the mouthpiece portion comprises simultaneously co-extruding the corrugated core and at least one planar support to form the mouthpiece portion.

[0035] These features allow the mouthpiece portion to be produced in a single extrusion step, making the production of flat consumable articles easier and faster, as the mouthpiece portion can be produced continuously through continuous extrusion.

[0036] According to some embodiments, the step of attaching the tobacco portion and the mouthpiece portion to one another includes enclosing at least the mouthpiece portion in a wrapper.

[0037] These features make it easier to wrap the mouthpiece portion, as the planar support provides support for the corrugated core during wrapping.

[0038] The invention and its advantages will be better understood on reading the following description, given purely by way of non-limiting example and made with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0039] [Figure 1] 1 is a perspective view of an aerosol generating assembly including an aerosol generating device and a flat consumable article according to the present invention. [Figure 2] FIG. 2 is a simplified perspective view of the flat consumable article of FIG. 1. [Figure 3] 1 is a partial perspective view of a flat consumable article according to a first embodiment of the present invention. [Figure 4] FIG. 4 is a front view of the flat consumable article of FIG. 3. [Figure 5] FIG. 4 is a partial perspective view of a corrugated core of the flat consumable article of FIG. 3. [Figure 6] FIG. 10 is a partial perspective view of a flat consumable product according to a second embodiment of the present invention. [Figure 7] FIG. 10 is a partial perspective view of a flat consumable product according to a third embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0040] Before the present invention is described, it is to be understood that the invention is not limited to the details of construction set forth in the following description. It will be apparent to one skilled in the art having the benefit of this disclosure that the invention is capable of other embodiments and of being practiced or carried out in various ways.

[0041] As used herein, the terms "aerosol-generating device" or "device" may include a vaping device for delivering aerosol, including aerosol for vaping, to a user using a heater element, as described in more detail below. The device may be portable. "Portable" may refer to a device used while held by a user. The device may be adapted to generate a variable amount of aerosol (as opposed to a fixed amount of aerosol), e.g., by activating a heater element, for a variable amount of time, which may be controlled by a trigger. The trigger may be user-activated, such as a vaping button and / or an inhalation sensor. The inhalation sensor may be sensitive to inhalation intensity and inhalation duration, allowing for the provision of a variable amount of vapor (to mimic the smoking effect of a conventional combustible smoking article, such as a cigarette, cigar, or pipe). The device may include a temperature regulation control for driving the temperature of the heater and / or heated aerosol-generating material (aerosol precursor) to a specific target temperature and then maintaining the temperature at that target temperature to enable efficient generation of aerosol.

[0042] As used herein, the term "aerosol" may include a suspension of vaporizable material, such as one or more of solid particles, liquid droplets, and gas. The suspension may be in a gas, including air. Aerosol herein may generally refer to / include a vapor. The aerosol may include one or more components of the vaporizable material.

[0043] As used herein, the terms "vaporizable material" or "precursor" may refer to smokable material, which may include, for example, nicotine or tobacco and an aerosol-forming agent. Tobacco may take the form of various materials, such as cut tobacco, granulated tobacco, tobacco leaf, and / or reconstituted tobacco. Suitable aerosol-forming agents include polyols (such as sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol), non-polyols (such as monohydric alcohols), acids (such as lactic acid), glycerol derivatives, esters (such as triacetin), triethylene glycol diacetate, triethyl citrate, glycerin, or vegetable glycerin. In some embodiments, the aerosol-generating agent may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The substrate may also include at least one of a gelling agent, a binder, a stabilizer, and a humectant.

[0044] First embodiment of the present invention Figure 1 shows an aerosol-generating assembly 1 according to the present invention. The aerosol-generating assembly 1 comprises an aerosol-generating device 10 and an aerosol-generating substrate 30, also referred to as a flat consumable article 30. The aerosol-generating device 10 is intended to operate with a flat consumable article 30 according to a first embodiment of the present invention, which is shown in more detail in Figures 2 to 5.

[0045] 1 , the aerosol generating device 10 includes a device body 12. The device body 12 extends along a device axis X and includes at least one sidewall 14. The device body 12 further includes a mouthpiece 16 and a housing 18 arranged consecutively along the device axis X. For example, the mouthpiece 16 and the housing 18 are two distinct parts.

[0046] For example, the mouthpiece 16 includes a cavity 20 extending along the device axis X. In particular, the cavity 20 is designed to receive the flat consumable article 30 such that the device axis X coincides with the article axis Y, as will be described in further detail below. For example, the cavity 20 has a cross-sectional shape substantially similar to the cross-sectional shape of the flat consumable article 30. The cavity 20 is, for example, a through hole extending along the device axis X.

[0047] Housing 18 defines an interior space of device 10 that houses various elements designed to perform different functions of device 10. This interior space can house, for example, a battery for powering device 10, a control module for controlling the operation of device 10, a heating chamber (not shown) for heating flat consumable article 30, and at least one heating element (not shown) for heating the heating chamber.

[0048] Referring to FIG. 2 , the flat consumable article 30 is, for example, a flat rectangular parallelepiped. The flat consumable article 30 extends substantially along an article axis Y and in an article plane A parallel to the article axis Y. The consumable article 30 exhibits a length L, a width W, and a height H. The length L is measured along the article axis Y between two opposing ends of the article 30. The width W is measured perpendicular to the article axis Y in the article plane A between the two opposing ends of the article 30. The height H is measured perpendicular to the article axis Y and perpendicular to the article plane A between the two opposing ends of the article 30. For example, being flat means that the height H is much smaller than both the length L and the width W. In particular, the height H is 5 to 50 times smaller than the length L or the width W. In a typical example, the length L of the consumable article 30 is substantially equal to 33 mm, and the width W and height H of the consumable article 30 are substantially equal to 12 mm and 1.2 mm, respectively. According to a different example, the values ​​L, W and H can be chosen, for example, within a range of ±40% of the values ​​mentioned above.

[0049] The flat consumable article 30 includes a tobacco portion 32 and a mouthpiece portion 34 arranged along the article axis Y. In other words, the tobacco portion 32 and the mouthpiece portion 34 are aligned along the article axis Y. The tobacco portion 32 and the mouthpiece portion 34 may be arranged consecutively along the article axis Y. Alternatively, an intermediate element (not shown in the drawings) may be arranged between the tobacco portion 32 and the mouthpiece portion 34. For example, the intermediate element may be a filter plug. For example, the consumable article 30 further includes a wrapper 70. Along the article axis Y, the flat consumable article 30 includes an abutment end 40 intended to be inserted into the cavity 20 of the mouthpiece 16 of the device 10, in particular into the heating chamber of the device 10, and a mouthpiece end 42 opposite the abutment end 40. For example, the length L of the article 30 is measured between the abutment end 40 and the mouthpiece end 42.

[0050] The tobacco portion 32 includes a tobacco substrate. The tobacco portion 32 is intended to be heated by a heater (in this example, using a heating chamber) and includes a vaporizable material as defined above. As shown in Figure 2, the tobacco portion 32 includes a sidewall 33 that extends substantially parallel to the article axis.

[0051] For example, the mouthpiece portion 34 is intended to be received within the mouthpiece 16 (as shown in FIG. 1). In some non-illustrated examples, the mouthpiece portion 34 itself forms a mouthpiece intended to contact the user's mouth and / or lips. As shown in FIG. 2, the mouthpiece portion 34 includes a planar side 35, which is flush with the sidewall 33 of the tobacco portion 32. As shown in FIGS. 3-5, the mouthpiece portion 34 includes a corrugated core 50 and at least a planar support 60, advantageously at least two planar supports 60, configured to support the corrugated core 50. According to a non-illustrated example, the mouthpiece portion 34 includes one planar support 60. According to the example shown in FIGS. 3 and 4, the mouthpiece portion 34 includes two planar supports 60, advantageously positioned on either side of the corrugated core 50 relative to the article plane A.

[0052] The corrugated core 50 is attached to at least one planar support 60. As shown in FIG. 4, the corrugated core 50 defines a first boundary plane P1 and a second boundary plane P2, both of which extend substantially parallel to the article plane A. The corrugated core 50 extends between the first boundary plane P1 and the second boundary plane P2. As shown in FIG. 4, the orthogonal projection of the corrugated core 50 onto the article plane A is included in the orthogonal projection of the at least one planar support 60 onto the article plane A. The corrugated core 50, together with the at least one planar support 60, defines a plurality of channels 51 extending substantially parallel to the article axis Y. According to the example shown in FIGS. 3 to 5, the corrugated core 50 includes a sheet 52. For example, the corrugated core 50 is made of paper or cardboard. Advantageously, the corrugated core 50 is adhered to the at least one planar support 60. According to a specific embodiment, the corrugated core 50 is made of paper or cardboard laminated with a thermoplastic material. In this embodiment, the corrugated core 50 can be welded to at least one planar support 60.

[0053] For example, the flow channels 51 may be bounded by the corrugated core 50 and the planar support 60, or may be bounded by the corrugated core 50 and the wrapper 70. The flow channels 51 provide a passageway for steam to flow toward the user's mouth.

[0054] Advantageously, the sheet 52 of the corrugated core 50 extends between two delimiting planes P1, P2. The sheet 52 includes two opposing non-planar surfaces 54 (or corrugated surfaces). For example, each of the non-planar surfaces 54 is characterized by a directrix D (shown in FIGS. 4 and 5 ) corresponding to a non-zero periodic function and a generatrix G (shown in FIG. 5 ) that is a straight line substantially parallel to the article axis Y. In particular, each non-planar surface 54 is formed by a generatrix G extending from the directrix D. For example, the directrix D corresponds to a sine wave function, a square wave function, a triangular wave function, or a sawtooth wave function. According to the example of FIGS. 3-5 , the directrix D corresponds to a truncated triangular wave function. By "truncated triangular wave function" is meant that the directrix D corresponds to a triangular wave function, the ordinate of which is limited between a truncated maximum value and a truncated minimum value, the truncated maximum value being less than the maximum value of the corresponding triangular wave function, and the truncated minimum value being less than the minimum value of the corresponding triangular wave function. In other words, in this example, as shown in Figures 3 to 5, the directrix D corresponds to a trapezoidal wave function. Advantageously, the period of the function of the directrix D is not constant. In particular, the directrix D may exhibit a first portion of the function having a first period and a second portion of the function having a second period, the second period being different from the first period.

[0055] Each non-planar surface 54 of sheet 52 includes a longitudinal edge 56 that extends longitudinally along article axis Y.

[0056] The longitudinal edges 56 of the non-planar surfaces 54 correspond to lines or minor surfaces of said non-planar surfaces 54 extending substantially parallel to the article axis Y. For example, as shown in FIG. 4, the longitudinal edges 56 of the first non-planar surface 54 of the sheet 52 extend in a first delimiting plane P1, and the longitudinal edges 56 of the second non-planar surface 54 of the sheet extend in a second delimiting plane P2. According to the examples of FIGS. 3 to 5, the longitudinal edges 56 are planar surfaces substantially parallel to the article axis A. According to examples not shown, the longitudinal edges 56 are straight lines substantially parallel to the article axis A, particularly when the directrix D corresponds to a sinusoidal, triangular, or sawtooth wave function. Advantageously, the longitudinal edges 56 are glued or welded to the planar support 60 facing the longitudinal edges 56.

[0057] Advantageously, the at least one planar support 60 contacts the longitudinal edge 56 of the first non-planar surface 54. According to the example shown in Figures 3 and 4, the first planar support 60 contacts the longitudinal edge 56 of the first non-planar surface 54, and the second planar support contacts the longitudinal edge of the second non-planar surface 54. For example, the at least one planar support is attached to the wrapper 70, in particular glued or welded to the wrapper 70. For example, the at least one planar support 60 essentially consists of paper, cardboard, or a film such as an adhesive film, a stain-resistant film, or a moisture-resistant film. According to a specific example, the at least one planar support 60 consists of paper or cardboard laminated with a thermoplastic material. In this example, the corrugated core 50, in particular the longitudinal edge 56, can be welded to the at least one planar support 60. 3, the corrugated core 50 and the at least one planar support 60, here two planar supports 60, are separate parts. The at least one planar support 60 may present a flat or raised surface.

[0058] As shown in Figures 2, 3, and 4, the wrapper 70 encases at least the mouthpiece portion 34. In particular, as shown in Figure 2, the wrapper 70 encases both the tobacco portion 32 and the mouthpiece portion 34. For example, the wrapper 70 attaches the tobacco portion 32 and the mouthpiece portion 34 to one another. In an example not shown, the wrapper 70 includes two separate portions, a first portion encasing the tobacco portion 32 and a second portion encasing the mouthpiece portion 34. The first portion 70 of the wrapper is not integral with the second portion 70 of the wrapper. The tobacco portion 32 and the mouthpiece portion 34 may be secured to one another by other suitable means.

[0059] The wrapper 70 can be composed of paper and / or nonwoven fabric and / or aluminum. For example, the wrapper 70 is made of a single layer. In a variation, the wrapper 70 is made of at least two layers. Preferably, the portion of the wrapper 70 enclosing the tobacco portion 32 includes an outer paper layer and an inner aluminum layer. The outer paper layer can extend to enclose the mouthpiece portion 34, and the inner aluminum layer can be shorter so as to enclose only the tobacco portion 32. Alternatively, the wrapper 70 includes an inner paper layer and an outer aluminum layer. In this case, the inner paper layer can be longer than the outer aluminum layer. In a variation, the aluminum layer, whether inner or outer, encloses the entire mouthpiece portion.

[0060] The wrapper 70 may be porous or air-impermeable. In embodiments, at least a portion of the wrapper 70 may be made of an air-impermeable material. The wrapper 70 may include a dedicated ventilation area. The ventilation area may be positioned within the portion of the wrapper that encases the mouthpiece portion 34. The ventilation area may be formed by air openings provided through the wrapper 70. The air openings may also be formed through the flat or planar support 60. For example, the air openings may be formed as a series of perforations extending along a direction perpendicular to the article plane A of the consumable article 30 or in a direction parallel to the article plane A and perpendicular to the article axis Y. The air openings (e.g., each 0.2 mm to 0.6 mm in diameter or longer) may be formed by laser cutting or any other suitable technique. Because the planar side 35 of the mouthpiece portion 34 is flush with the sidewall 33 of the tobacco portion 32, the article 30 appears to be one piece to the touch when both the tobacco portion 32 and the mouthpiece portion 34 are wrapped in a single wrapper 70. This makes the article 30 easier to manufacture and more pleasant to the user.

[0061] A method for manufacturing the flat consumable article 30 will now be described. First, the method includes the step of providing a tobacco portion 32. Next, the method includes the step of fabricating a mouthpiece portion 34 such that the corrugated core is attached to at least one planar support 60. For example, fabricating the mouthpiece portion 34 includes the substep of attaching the corrugated core 50 and at least one planar support 60. The corrugated core 50 is preferably glued or welded to the at least one planar support 60. Thanks to the rigidity provided by the support 60, the mouthpiece portion 34 can be handled without risk of deformation. According to a specific example, for productivity reasons, the mouthpiece portion 34 can be formed by providing elongated corrugated core elements and elongated support elements attached (e.g., glued or welded) to each other, and then cut into segments corresponding to the individual mouthpiece portions 34. By "elongated," we mean that the elongated corrugated core elements and elongated support elements have dimensions greater than the dimensions, measured along the article axis Y, of the mouthpiece portion 34 to be fabricated. In other words, both the elongated corrugated core element and the elongated support element are formed from a continuous elongated sheet, which is then attached to one another to form an elongated assembly. The elongated assembly is then cut to the desired length to form the mouthpiece portion 34. According to another example, the corrugated core 50 and the at least one planar support 60 are made by extrusion. For example, the corrugated core 50 may be formed, for example, by first providing a planar elongated sheet 52 and then corrugating the elongated sheet 52 to obtain a corrugated elongated sheet 52. According to another example, the corrugated core 50 is formed, particularly by extrusion, by providing an already corrugated elongated sheet 52. Next, the method includes the step of sequentially arranging the tobacco portion 32 and the mouthpiece portion 34 along the article axis Y. Finally, the method includes the step of attaching the tobacco portion 32 and the mouthpiece portion 34 to one another. For example, the step of attaching the tobacco portion 32 and the mouthpiece portion 34 to one another may include wrapping at least the mouthpiece portion 34 in a wrapper 70. In particular, both the tobacco portion 32 and the mouthpiece portion 34 are enclosed by a wrapper 70 .

[0062] Second embodiment of the present invention FIG. 6 shows a flat consumable article 130 according to a second embodiment of the present invention. The flat consumable article 130 of the second embodiment is similar to the flat consumable article 30 of the first embodiment, except that the corrugated core 150 and at least one planar support 160 (here, two planar supports 160) are made as a single piece. For example, the corrugated core 150 and at least one planar support 160 are formed by a single continuous sheet 152. In particular, the sheet 152 includes at least an end 152A corresponding to the at least one planar support 160 and a corrugation portion 153 corresponding to the corrugated core 150. In the example of FIG. 6, the sheet 152 includes a first end 152A corresponding to the first planar support 160, a second end 152B corresponding to the second planar support 160, and a corrugation portion 153 corresponding to the corrugated core 150, which is disposed between the first end 152A and the second end 152B. Advantageously, as shown in Figure 6, opposite side edges of the corrugated core 150 are formed as integral parts of the first and second planar supports 160, respectively. As shown in Figure 6, the first and second ends 152A, 152B are folded against the corrugations 153 so that each planar support 160 contacts the longitudinal edge 156 of the corresponding non-planar surface 154. This further enhances the deformation resistance of the flat consumable article 130. Furthermore, because the corrugated core 150 and the at least one planar support 160 are made as a single piece, it becomes easier to wrap the corrugated core 150 and the at least one planar support 160 in a wrapper 170.

[0063] The method for manufacturing the flat consumable article 130 according to the second embodiment of the present invention is similar to the method described above. Advantageously, the step of making the mouthpiece portions 34 also includes, before the attaching substep, a substep of folding the single continuous sheet 152 so that the at least one planar support 160 contacts the longitudinal edge 156 of the corresponding non-planar surface 154. For example, before the folding substep, the corrugated core 150 and the at least one planar support 160 are made by extrusion. Advantageously, the corrugated core 150 and the at least one planar support 160 are co-extruded simultaneously. According to a specific example, for productivity reasons, the mouthpiece portions 34 can be formed by providing an elongated continuous sheet 152, which, after the folding and attaching substeps, is cut into segments corresponding to the individual mouthpiece portions 34.

[0064] Third embodiment of the present invention 7 shows a flat consumable article 230 according to a third embodiment of the present invention. The flat consumable article 230 of the third embodiment is similar to the flat consumable article 130 of the second embodiment, except that the longitudinal edges 256 are formed as an integral part of at least one planar support 260. In other words, in the third embodiment, the non-planar surface 254 and at least a portion of the longitudinal edges 256 are imaginary. In particular, there is no physical boundary between the longitudinal edges 256 and the portion of the non-planar surface 254 extending opposite the longitudinal edges. Thus, because the corrugated core 250 and the at least one planar support 260 are made as a single piece, and because the longitudinal edges 256 are formed as an integral part of the at least one planar support 260, the corrugated core 250 and the at least one planar support 260 are attached. In the third embodiment, "the corrugated core 250 includes the sheet 252" means that the corrugated core 250 includes a portion similar to the sheet 52, 152 of the first and second embodiments, except that the corrugated core 250 is integrated with at least one support 260 at the height of each longitudinal edge 256. This further enhances the deformation resistance of the flat consumable article 230. Furthermore, because there are multiple continuous joints between the corrugated core 250 and the at least one planar support 260, it becomes easier to wrap the corrugated core 250 and the at least one planar support 260 with a wrapper 270.

[0065] The method for manufacturing the flat consumable article 130 according to the second embodiment of the present invention is similar to the first embodiment of the method, except that the step of making the mouthpiece portion 34 includes a substep of simultaneously co-extruding the corrugated core 250 and at least one planar support 260 to form the mouthpiece portion 34. In other words, the corrugated core 250 and the at least one planar support 260 are simultaneously formed as one piece by extrusion. That is, the mouthpiece portion 34 is formed by simultaneously co-extruding the corrugated core 250 and the at least one planar support 260. Advantageously, compared to the first and second embodiments, in this third embodiment, it is not necessary to attach the corrugated core 250 to the at least one planar support 260. According to a specific example, for productivity reasons, the mouthpiece portion 34 can be formed by extruding a continuous, elongated single piece (which, in the third embodiment, is composed of elongated core elements and elongated support elements), which is then cut into segments corresponding to the individual mouthpiece portions 34.

Claims

1. A flat consumable article (30; 130; 230) for an aerosol generating device (10), the flat consumable article (30; 130; 230) extending along an article axis (Y) and along an article plane (A) parallel to the article axis (Y), the flat consumable article (30; 130; 230) comprising a tobacco portion (32) and a mouthpiece portion (34) arranged along the article axis (Y); The mouthpiece portion (34) comprises the corrugated core (50; 150; 250) and at least one planar support (60; 160; 260) that supports the corrugated core (50; 150; 250), and the corrugated core (50; 150; 250) is attached to the at least one planar support (60; 160; 260), a flat consumable article (30; 130; 230).

2. 2. The flat consumable article (30; 130; 230) of claim 1, wherein the corrugated core (50; 150; 250), together with the at least one planar support (60; 160; 260), defines a plurality of flow channels (51) extending substantially parallel to the article axis (Y).

3. 3. The flat consumable article (30; 130; 230) of claim 1 or 2, wherein the corrugated core material (50; 150; 250) comprises a sheet (52; 152; 252), the sheet (52; 152; 252) comprising two opposing non-planar surfaces (54), the non-planar surfaces (54) being formed by a generatrix (G) that is a straight line substantially parallel to the article axis (Y), the generatrix extending from a directrix (D) corresponding to a non-zero periodic function.

4. 4. The flat consumable article (30; 130; 230) of claim 3, wherein each non-planar surface (54) of the sheet (52; 152; 252) includes a longitudinal edge (56; 156; 256) extending longitudinally along the article axis (Y), and wherein the at least one planar support (60; 160; 260) contacts the longitudinal edge (56; 156; 256) of the corresponding non-planar surface (54).

5. A flat consumable article (30; 130; 230) as described in claim 3 or 4, wherein the orthogonal projection of the corrugated core material (50; 150; 250) onto the article plane (A) is included in the orthogonal projection of the at least one planar support (60; 160; 260) onto the article plane (A).

6. The flat consumable article (30; 130) according to any one of claims 1 to 5, wherein the corrugated core (50; 150) is glued or welded to the at least one planar support (60; 160).

7. The flat consumable article (30; 130; 230) according to any one of claims 1 to 6, wherein the at least one planar support (60; 160; 260) is made of paper, cardboard or film.

8. The flat consumable article (30; 130; 230) according to any one of claims 1 to 7, further comprising a wrapper (70; 170; 270) encasing at least the mouthpiece portion (34).

9. 9. The flat consumable article (30; 130; 230) of claim 8, wherein the at least one planar support (60; 160; 260) is attached to the wrapper (70; 170; 270).

10. A flat consumable article (30; 130; 230) according to any one of claims 1 to 9, comprising at least two planar supports (60; 160; 260) configured to support the corrugated core (50; 150; 250).

11. A flat consumable article (30; 130; 230) as described in claim 10 when considered in combination with claim 4, wherein each planar support (60; 160; 260) contacts the longitudinal edge (56; 156; 256) of the corresponding non-planar surface (54).

12. A method for producing a flat consumable article (30; 130; 230) according to any one of claims 1 to 11, comprising the steps of: - providing said tobacco portion (32); - preparing said mouthpiece part (34) so ​​that said corrugated core (50; 150; 250) is attached to said at least one planar support (60; 160; 260); - positioning said tobacco portion (32) and said mouthpiece portion (34) along said article axis (Y); - attaching said tobacco portion (32) and said mouthpiece portion (34) to each other; A method comprising:

13. 13. The method of claim 12, wherein the step of fabricating the mouthpiece portion (34) comprises attaching the corrugated core (50; 150) and the at least one planar support (60; 160) to form the mouthpiece portion (34).

14. 13. The method of claim 12, wherein the step of fabricating the mouthpiece portion (34) includes forming the mouthpiece portion (34) by simultaneously co-extruding the corrugated core material (250) and the at least one planar support (260).

15. 15. The method of any one of claims 12 to 14, wherein the step of attaching the tobacco portion (32) and the mouthpiece portion (34) to one another comprises wrapping at least the mouthpiece portion (34) in a wrapper (70; 170; 270).

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